22 nd January 2003 File Reference: u:\Guidelines - BlueScope Lysaght PowerPoint Template Port Kembla Steelworks Blast Furnace Technology & Ironmaking Process RBS Investor Lunch OSCAR GREGORY , General Manager Iron & Slab Australian and NZ Steel Manufacturing Businesses October 2010
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Port Kembla Steelworks 22nd January 2003 Blast Furnace ...clients.weblink.com.au/news/asx_pdf_loader3.asp?... · Blast Furnace Technology & Ironmaking Process RBS Investor Lunch OSCAR
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OSCAR GREGORY, General Manager Iron & SlabAustralian and NZ Steel Manufacturing Businesses
October 2010
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Important notice
THIS PRESENTATION IS NOT AND DOES NOT FORM PART OF ANY OFFER, INVITATION OR RECOMMENDATION IN RESPECT OF SECURITIES. ANY DECISION TO BUY OR SELL BLUESCOPE STEEL LIMITED SECURITIES OR OTHER PRODUCTS SHOULD BE MADE ONLY AFTER SEEKING APPROPRIATE FINANCIAL ADVICE. RELIANCE SHOULD NOT BE PLACED ON INFORMATION OR OPINIONS CONTAINED IN THIS PRESENTATION AND, SUBJECT ONLY TO ANY LEGAL OBLIGATION TO DO SO, BLUESCOPE STEEL DOES NOT ACCEPT ANY OBLIGATION TO CORRECT OR UPDATE THEM. THIS PRESENTATION DOES NOT TAKE INTO CONSIDERATION THE INVESTMENT OBJECTIVES, FINANCIAL SITUATION OR PARTICULAR NEEDS OF ANY PARTICULAR INVESTOR.
THIS PRESENTATION CONTAINS CERTAIN FORWARD-LOOKING STATEMENTS, WHICH CAN BE IDENTIFIED BY THE USE OF FORWARD-LOOKING TERMINOLOGY SUCH AS “MAY”, “WILL”, “SHOULD”, “EXPECT”, “INTEND”, “ANTICIPATE”, “ESTIMATE”, “CONTINUE”, “ASSUME” OR “FORECAST” OR THE NEGATIVE THEREOF OR COMPARABLE TERMINOLOGY. THESE FORWARD-LOOKING STATEMENTS INVOLVE KNOWN AND UNKNOWN RISKS, UNCERTAINTIES AND OTHER FACTORS WHICH MAY CAUSE OUR ACTUAL RESULTS, PERFORMANCE AND ACHIEVEMENTS, OR INDUSTRY RESULTS, TO BE MATERIALLY DIFFERENT FROM ANY FUTURE RESULTS, PERFORMANCES OR ACHIEVEMENTS, OR INDUSTRY RESULTS, EXPRESSED OR IMPLIED BY SUCH FORWARD-LOOKING STATEMENTS.
TO THE FULLEST EXTENT PERMITTED BY LAW, BLUESCOPE STEEL AND ITS AFFILIATES AND THEIR RESPECTIVE OFFICERS, DIRECTORS, EMPLOYEES AND AGENTS, ACCEPT NO RESPONSIBILITY FOR ANY INFORMATION PROVIDED IN THIS PRESENTATION, INCLUDING ANY FORWARD LOOKING INFORMATION, AND DISCLAIM ANY LIABILITY WHATSOEVER (INCLUDING FOR NEGLIGENCE) FOR ANY LOSS HOWSOEVER ARISING FROM ANY USE OF THIS PRESENTATION OR RELIANCE ON ANYTHING CONTAINED IN OR OMITTED FROM IT OR OTHERWISE ARISING IN CONNECTION WITH THIS.
Steel Production Processes – Integrated Plant and “Mini-Mill”
Flat Products “Mini-Mill”
EAF/Thin Slab Caster
Flat Products
Integrated Plant
Iron Ore
Coal
Coke
COKE OVEN
SINTERING
BLAST FURNACE
Slag
Molten pig iron
CONVERTER (BOF)
Sintered ore
“Graded” Liquid Steel
REFINING STAND
Slab
CONTINUOUS CASTING
ROLLING MILL
Hot Rolled Coils
REHEAT FURNACE
ROLLING MILL
“Graded” Liquid Steel
REFINING STAND
Scrap
& HBI
ELECTRIC ARC FURNACE
TUNNEL FURNACE
Raw liquid steel
Hot Rolled Coils
THIN SLAB CASTING
e.g. Port Kembla Steelworks e.g. NorthStar BSL
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Overview of Steel Production Process – Pt Kembla
Slab
Hot rolled strip mill
Cold rolled strip mill
Wide coil Narrow strip
Electrical coil Metal Coated coil
Cut lengths
PlateReversing mill
FLAT PRODUCTS
Painted coil Laminated coil
Tubes
Welded tube mill
CONVERTER (BOS)
COKE OVEN
Iron Ore
Coal
Coke
SINTERING
BLAST FURNACE
Slag
Molten pig iron
Sintered ore
“Graded” Liquid
Steel REFINING STAND
Slab
CONTINUOUS CASTING
ROLLING MILL
Hot Rolled Coils
REHEAT FURNACE
6
Overview of Steel Production Process
Run out tablecooling
Minimill Thin-Slab Casting – 1 to 2 Mt/a
– 300 to 400 m4-6 m/minute
50-60mm thickHolding furnace
Finisher
300-400 m
1-10mm thick
Coiler
20-40 metric ton coil
Integrated “Conventional” Slab Casting – 3 to 5 Mt/a
– 500 to 800 m
200-300 mm thick
20-40 metric ton coil
1-2m/minute
Gas cutter
Cooling
Reheat furnace
RougherCoil box Finisher
1-10mm thick
Coiler
500-800 m
Run out tablecooling
Strip Casting – 0.5 Mt/a
– 60 m15-150 m/minute
Scale ControlChamber
20-40 metric ton coil
0.7 - 1.8 mm thick
60 m
Mill
Coiler
Run out tablecooling
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Steel Production – NZS has a Unique Process
Continuous
Casting
Machine
MHF 5
MHF 4
MHF 3
MHF 2
PC
Coal
&
Limestone
Kiln 5
Kiln 4
Kiln 3
Kiln 2
Storage Hopper
Liquid Raw Iron &
Vanadium Slag
Weigh
BridgeVanadium Slag
VRU LTS
Steel
Slag
Slag
Melter 1
Dry PC &
Electricity
KOBM
Slag
Processed
Liquid
Iron
Slab
KOBM/LTSKILNS MELTERS CCM
Scrap
Continuous Ironmaking Process Batch Slabmaking Process
Millscale
Added
Millscale
Added
MHF Off-Gas
Kiln Off-Gas
Melter Off-Gas
To Electricity Grid
MHF Cogeneration Kilns Cogeneration
RPCC
Fluxes
Ironsand From
Mine
Melter 2
Dry PC &
Electricity
8
Markets and Supply Chain – Port Kembla
Building &
Construction
Export
Domestic
Distributors
Distribution
& Solutions
Australia
Direct
Manufacturing
Pipe & Tube
Western Port
Illawarra
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Consumption of primary raw materials at Port Kembla Steelworks
Note: (1) coking coal volumes shown are dry tonnes; market pricing is typically for wet tonnes, 8% moisture content difference to dry tonnes
(2) measure shows tonnage rate used in steel making, and excludes coal used for export coke making
(3) 40% of scrap feed is sourced externally; balance, internally sourced scrap.
Indicative use rate
FY2008 FY2009 FY2010 per slab tonne
Iron Ore
Fines 4.0 2.9 4.0 0.97t
Lump 1.6 1.0 1.5 0.31t
Pellets 2.3 1.6 1.5 0.24t
Total 7.9 5.5 7.0 1.51t
Coal
Coking (1)
3.0 2.2 2.7 0.49t
PCI 0.6 0.4 0.7 0.14t
Anthracite 0.1 0.0 0.0 0.02t
Total 3.7 2.6 3.4 0.65t
Scrap (3)
1.0 0.7 0.9 0.2t
Raw Steel Production 5.3 3.5 4.7
Export Coke Despatches 264kt 282kt 175kt
Volume consumed in production (dry mt)
Reflects mix shift
from sinter plant
upgrade
(+1.1mtpa fines,
-1.0mtpa pellets)
Possible slight
shift towards
higher PCI use
in future in lieu
of hard coking
coal
Includes
around 300kt
consumed
for export
coke
despatches
(2)
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Notes:
(1) Slab, HRC and plate. Variances of totals from sum of constituents is be due to rounding
(2) See Coated Australia Annual Capacities slide for Western Port Works capacities
(3) Domestic HRC ex Port Kembla Steelworks only; ie excludes export HRC despatches from Western Port when reconciling from the ASX Release, Attachment 1
(4) Export HRC ex Port Kembla Steelworks only; ie excludes export HRC despatches from Western Port when reconciling from the ASX Release, Attachment 1
(5) See Coated Australia Annual Capacities slide for Springhill Works capacities
(6) See ASX Release, Attachment 1 for detail
PKSW – Production & Despatch Flow
Domestic21 0
Port Kembla Steelworks
Slab ProductionFY 2010 FY 2009
4,724 3,517
Domestic555(3) 425
Interco985 796
Domestic1,011 900
Export535(4) 409
Interco1,558 1,241
HRC2,648 2,075
Export547 341
Domestic85 72
Interco85 72
Export43 46
Domestic183 175
Plate311 293
Western Port (2)
Springhill(5) /
Distribution
Asia / Nth
Am(6)
Distribution
Slab 1,678 1,098
Hot Strip Mill
Plate Mill
Product / DestFY10 kt FY09 kt
Legend:
Port Kembla Steelworks
Despatches(1)
FY 2010 FY 2009
4,636 3,466
Inventory movements
& yield losses
Export672 302
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Cokemaking
16
12
GAS
PROCESSING
COKE SCREEN
3.0Mtpa
BLENDED COAL
COKE PLANT
2.3Mtpa COKE
SOLIDS
Cokemaking Process Overview
TARSULPHATE
39Kt 86Kt
BTX
(Benzene)
23ML
COKE OVENS GAS 19,000TJ
Interworks energy (boilers,
furnaces)
BREEZE(< 10 mm)
NUT(10 – 25 mm)
LUMP(25 – 80 mm)
TATA(20 – 50 mm)
86%
7%
2%
5%
Coke usage
Blast furnaces 1.9Mtpa
Sinter plant 0.2Mtpa
Export 0.2Mtpa
2.3Mtpa
Export coke
BlueScope approach is to sell excess production on a spot basis.
Generally offered in 30-45kt cargo sizes.
1 tonne of coke solids is equivalent to 1.30t coking coal
Types of coke solids produced
•Lump•Tata•Nut•Breeze
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Coke Ovens Process
Coal is blended and charged into an oven
The coal is levelled to allow passage for the gas generated to exit
OVEN
DOORS
STANDPIPE
GAS PASSAGE
COAL MASS
After levelling
CHARGE HOLES
For Filling Oven with coal
CHUCK
DOOR
COLLECTOR
MAIN
OVEN
DOORS
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Regenerators
• Air and gas are preheated by separate regenerators and the heat distributed across the refractories next to the oven wall
• The oven heats the coal for approx 19-20 hrs – driving off the volatiles, leaving behind relatively pure carbon (88%) + ash (10-12%) in what is termed coke.
• The surplus gas produced (Coke Ovens Gas (COG) and other by-products (Ammonium Sulphate, Benzene, Tar) are collected
• The coke is pushed from the oven and quenched with water
• Coke is then mixed with iron ore in the Blast Furnace to make iron
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REFRACTORY BRICK - HEATED
Coal & Cokemaking Course March, 2010 15
What is Metallurgical Coke?
Desirable physical properties
• strong and large lumps
• withstand the blast furnace environment without generating fines
• an irregular shape, so that it doesn‟t pack tightly (permeability)
• very porous (react with Blast)
Chemical properties
• Low Sulphur & Phosphorus ( Steel quality)
• Low Ash (less slag, less fuel, lower hot metal cost)
Solid residue after pyrolysis of a coking coal• the coal is heated to >1000ºC in the absence of air
• largely carbon plus some hydrogen, nitrogen, sulphur and inorganic minerals
Coal & Cokemaking Course March, 2010 16
Coking and Non-Coking Coals
Only a limited range of coals are suitable for making metallurgical coke
• bituminous coals
• need to exhibit plasticity and swelling
• depending on the quality of the coke produced can be classified as hard, semi-hard, semi-soft or soft coking coals
Non-coking coals form a char when heated
• fine powder approximately the same size as the original coal
Key processes that form metallurgical coke during pyrolysis
• Softening, swelling (dilatation) and agglomeration
Binds individual coal particles into large lumps; feed coal typically 85% < 3.35 mm to coke with mean size 50 mm.
• Shrinkage
Affects coke size, strength and oven wall pressure (OWP) through the generation of fissures and micro-fissures